1987 3.2 Carrera Backdate project - Sladeys hotrod
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
OK so that was yesterday....
Today I got down to the sunroof.
Before I started I made a template of the profile of the roof
Then laid the replacement panel on for size - ok from the front
But looks a bit long from the side
Today I got down to the sunroof.
Before I started I made a template of the profile of the roof
Then laid the replacement panel on for size - ok from the front
But looks a bit long from the side
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
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- Nurse, I think I need some assistance
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Followed the instructions in the Bentley manual to take the sunroof itself out. Then started work on the cassette holding it all in. Chopped the supporting bars at the side, and then put a heat gun on the glue. This is part way through
It's joined around the top of the opening as well - so I decided to take a grinder with a flap disc round the edge of that to cut it free
Then starting from the back, applied more heat to the glue and started to loosen it off. The whole cassette is slightly too wide to drop down though so cutting it down the middle allows it to fold in and fall down, and you're left with this
Then drew round the new panel
And cut it out
Tomorrow we weld!!!
It's joined around the top of the opening as well - so I decided to take a grinder with a flap disc round the edge of that to cut it free
Then starting from the back, applied more heat to the glue and started to loosen it off. The whole cassette is slightly too wide to drop down though so cutting it down the middle allows it to fold in and fall down, and you're left with this
Then drew round the new panel
And cut it out
Tomorrow we weld!!!
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
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- Nurse, I think I need some assistance
- Posts: 8720
- Joined: Sat Apr 23, 2005 9:08 pm
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Hmmm not feeling thathot66 wrote:think you should paint the strengthening gussets a contrasting colour
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
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- Nurse, I think I need some assistance
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Someone has been on the brave pills!
Good luck!
Good luck!
Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Quite like the idea of bright orange shock gussets in a black engine bay ....sladey wrote:Hmmm not feeling thathot66 wrote:think you should paint the strengthening gussets a contrasting colour
James
1973 911 2.4S
1993 964 C2
2010 987 Spyder
1973 MGB Roadster
Its not how fast you go, but how you go fast
1973 911 2.4S
1993 964 C2
2010 987 Spyder
1973 MGB Roadster
Its not how fast you go, but how you go fast
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Yeah Mark ! Go on SON !!!sladey wrote:
Tomorrow we weld!!!
# 465
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
1967 912 Polo Red
1968 912/11 RAL 7001 ' MOD ROD '
1990 964 C2 Velvet Red
1991 VW Vanagon GL (SOLD - Vanagone)
2017 Coleman CT200U
“It’s not where you’re from, it's where you’re at”
Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
+1Gary71 wrote: Someone has been on the brave pills!
Good luck!
- Darren65
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
....yeh but is that brushed or sprayed!sladey wrote:Oh and painted it black which I believe is correct for a 72 car
Great progress Mark.
Darren
72T 2.5... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=56183
73 2.4E ... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=44242
77 Carrera 3.0...to 74 3.0RS ... http://ddk-online.com/phpBB2/viewtopic.php?f=28&t=63389
72T 2.5... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=56183
73 2.4E ... http://ddk-online.com/phpBB2/viewtopic.php?f=10&t=44242
77 Carrera 3.0...to 74 3.0RS ... http://ddk-online.com/phpBB2/viewtopic.php?f=28&t=63389
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1987 3.2 Carrera Backdate project - Sladeys hotrod
OK, roof weld day has arrived. First we drill ready for the plug welds
I used the template I'd made, to make another template that could be used from the inside - I kept that jammed up inside until all the welding had been done
I used some battens to prop the panel up
And I was then able to fit the cleco fasteners (they are so cool)
Gradually doing the plug welds, moving about to stop heat build up
Finally all welded up along with the cleco holes, and ground the welds flat
By about 3pm I was losing I heart as I was still fannying around getting it positioned correctly, but once I'd got a couple of fasteners in it all speeded up nicely, and the welding didn't take long at all
A satisfying days work
Tomorrow it's Filler Time
I used the template I'd made, to make another template that could be used from the inside - I kept that jammed up inside until all the welding had been done
I used some battens to prop the panel up
And I was then able to fit the cleco fasteners (they are so cool)
Gradually doing the plug welds, moving about to stop heat build up
Finally all welded up along with the cleco holes, and ground the welds flat
By about 3pm I was losing I heart as I was still fannying around getting it positioned correctly, but once I'd got a couple of fasteners in it all speeded up nicely, and the welding didn't take long at all
A satisfying days work
Tomorrow it's Filler Time
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
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- Nurse, I think I need some assistance
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Good going!
I have done similar in a larger opening a long time ago and getting started is the hardest bit. Just the fear of acute distortion to overcome!
Will you fully mig weld and lead or plug weld some more and lead the seam?
My 911 is due a back to metal re-paint and I have wondered if I should remove my cloth sun roof and replace with steel.
I have done similar in a larger opening a long time ago and getting started is the hardest bit. Just the fear of acute distortion to overcome!
Will you fully mig weld and lead or plug weld some more and lead the seam?
My 911 is due a back to metal re-paint and I have wondered if I should remove my cloth sun roof and replace with steel.
73T 911 Coupe, road/hillclimber 3.2L
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
Lola t 492 / 3.2 hillclimb racer
Boxster 987 Gen II 2.9
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- Nurse, I think I need some assistance
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Probably not either - I'm taking Jons lead http://www.classiccarreras.com/964%20Sunroof.html
Looking at his pictures again he's done more spot welds than my plug welds..... I may supplement with some more welds before filler
Looking at his pictures again he's done more spot welds than my plug welds..... I may supplement with some more welds before filler
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Mark,
Great stuff, told you the hard bit was removing the old roof, only thing I would do is run a seam weld around each of the corners, but again do it bit by bit to avoid distortion.
Also once all the weld is ground down go around the join with a hammer and dolly and just make sure the edge of the new panel is tight against the roof underneath.
Then it's on to the filler work, you will need a long flexible sanding block (about 12"x2.5") if you don't already have one. Like this http://www.jawel.co.uk/index.php?main_p ... ts_id=2905
Cheers
Jon
Great stuff, told you the hard bit was removing the old roof, only thing I would do is run a seam weld around each of the corners, but again do it bit by bit to avoid distortion.
Also once all the weld is ground down go around the join with a hammer and dolly and just make sure the edge of the new panel is tight against the roof underneath.
Then it's on to the filler work, you will need a long flexible sanding block (about 12"x2.5") if you don't already have one. Like this http://www.jawel.co.uk/index.php?main_p ... ts_id=2905
Cheers
Jon
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1987 3.2 Carrera Backdate project - Sladeys hotrod
Thanks Jon,
Only just read this so I'm already on the filler! I did another 20 welds along the edges including some extra in the corners - I reckon it'll be fine now - there's about 70-80 welds holding it in
I've already bought a long sander as well - useful things
Thanks for all your help on this and the sills Jon - I'd have struggled without it
Only just read this so I'm already on the filler! I did another 20 welds along the edges including some extra in the corners - I reckon it'll be fine now - there's about 70-80 welds holding it in
I've already bought a long sander as well - useful things
Thanks for all your help on this and the sills Jon - I'd have struggled without it
Last edited by sladey on Thu Apr 24, 2014 1:38 pm, edited 1 time in total.
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah
-
- Nurse, I think I need some assistance
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Well done Mark, really impressed with your new found skills and the epitome of the DDK spirit!
cheers, Mike.
previously..
1994 968 Club Sport Riviera Blue
1994 993 C2 Carrera Riviera Blue
1972 911S to Martini RSR Prototype Spec
1973 911E to RS Lightweight Specification
1981 924 Carrera GT ex Mexborough car
3.2 Carrera Sport x2
previously..
1994 968 Club Sport Riviera Blue
1994 993 C2 Carrera Riviera Blue
1972 911S to Martini RSR Prototype Spec
1973 911E to RS Lightweight Specification
1981 924 Carrera GT ex Mexborough car
3.2 Carrera Sport x2
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- Nurse, I think I need some assistance
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- Joined: Sat Apr 23, 2005 9:08 pm
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Re: 1987 3.2 Carrera Backdate project - Sladeys hotrod
Thanks Mike - very kind
The simple things you see are all complicated
I look pretty young but I'm just backdated yeah
I look pretty young but I'm just backdated yeah